Waterproof boat-like shell for footwear made by cement lasting process

ABSTRACT

A one-piece boat-like shell for footwear constructed from an injection-molded sole to which a last cemented upper is secured. The last cemented upper includes a vamp and heel counter each comprising a sheet of water impermeable vinyl secured about the periphery of a insole board and secured to the sole by a double bonding process.

SCOPE OF THE INVENTION

[0001] This invention relates to footwear and, particularly, bootshaving a preferably waterproof boat-like shell.

BACKGROUND OF THE INVENTION

[0002] Footwear and particularly boots are known which have a one-pieceboat-like shell comprising the sole, vamp and heel counterinjection-molded as from rubber or plastic compounds and to which anupper may be attached. The one-piece boat-like shell effectivelyprovides a waterproof lower-most portion of the boot which extendsacross the top of the toes upwardly to at least partially overlie theball of a user's foot, preferably to the instep and rearwardly to aboutthe heel. Such boots have been well received in the marketplace.However, they suffer the disadvantage that the same material is used forthe sole as for the vamp and the heel and must be formed by the sameprocess. A disadvantage of such boots as appreciated by the presentinventor is that they do not permit the advantageous use of differentmaterials for the sole, vamp and heel counter and do not permit use ofdifferent processes for manufacture and treating of the materials forthese various portions of the boot.

SUMMARY OF THE INVENTION

[0003] To at least partially overcome these disadvantages of previouslyknown devices, the present invention provides a construction for afootwear boat-like shell having an injection-molded sole of preferablylightweight rubber formed by injection-molding and to which an upperincluding a water impermeable vamp and heel counter formed to an insoleboard by a cement lasting process.

[0004] An object of the present invention is to provide a substitute fora conventional one-piece boat-like shell for footwear.

[0005] Another object is to provide a waterproof construction forfootwear formed by a cement lasting.

[0006] Another object is to provide a boat-like shell for footwearformed with an injection-molded sole and a vamp and a heel counter ofplastic, preferably vinyl, material carrying decorative markingsthereon.

[0007] Another objective is to provide an improved method forconstruction of a waterproof boat-like shell for footwear.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Further aspects and advantages of the present invention willbecome apparent from the following description taken together with theaccompanying drawings in which:

[0009]FIG. 1 is a pictorial view of a first preferred embodiment of aboot in accordance with the present invention;

[0010]FIG. 2 is a schematic exploded side view showing selectedcomponents of the boot of FIG. 1;

[0011]FIG. 3 is a side view of an assembly of the insole board, vamp andheel counter;

[0012]FIG. 4 is a cross-sectional view along line 4-4′ of FIG. 3;

[0013]FIG. 5 is a cross-sectional view along line 5-5′ in FIG. 3;

[0014]FIG. 6 is a top view of the assembly shown in FIG. 3;

[0015]FIG. 7 is a bottom view of the assembly shown in FIG. 3, however,with the filler 14 shown in place;

[0016]FIG. 8 is a schematic cross-section of a segment of the vamp shownin FIG. 4;

[0017]FIG. 9 is a side view of an assembly of a boat-like shell; and

[0018]FIG. 10 is a cross-sectional view along line X-X′ in FIG. 9.

DETAILED DESCRIPTION OF THE DRAWINGS

[0019] Reference is made first to FIG. 1 which shows an assembled boot10 in accordance with the first embodiment of the present invention.

[0020]FIG. 2 shows in a schematic exploded view various components ofthe boot. These components include a sole 12, a filler 14, an insoleboard 16, a vamp 18, a heel counter 20 and an upper generally indicated22.

[0021] The vamp 18 comprises a sheet member which is formed into agenerally U-shape as seen in FIG. 6 extending from one rear edge 30 to asecond rear edge 32 on opposite sides. An upper edge 34 is of a U-shapeand defines a major portion of an opening to receive a user's foottherethrough. As best seen in FIGS. 4, 5 and 7, a lower edge 36 of thevamp 18 wraps underneath the lower surface 38 of the insole board 16 andis secured thereto. The vamp 18 thus has a lasting allowance flange 40which is provided underneath the insole board 16 and extends about theperiphery of the insole board from one rear edge 30 to the other rearedge 32 of the vamp.

[0022] The vamp is shown to have a toe portion 42 which extends from thefront toe 44 of the vamp over an upper portion of a foot of a user tothe upper edge 34. At the forwardmost portion of the upper edge 34, thevamp preferably extends sufficiently high so that the toe portion 42extends rearwardly to provide continuous cover and preferablywaterproofing over the toe at least rearward of a ball of a foot andpreferably rearward to proximate where an instep commences.

[0023] The heel counter 20 comprises a sheet material which, as seen inFIG. 6, extends in a general U-shape from a front edge 46 on one side toa front edge 48 on the other side. The heel counter 20 extends upwardlyto an upper edge 50 and downwardly to a lower edge 52. The lower edge 52is underneath the insole board 16 and a lasting allowance flange 54 isprovided as part of the heel counter which extends underneath the insoleboard 16 and is bonded thereto.

[0024] On each side of the assembly shown in FIG. 3, the vamp 18 issecured to the heel counter 20 as along a stitched line shown at 56 inFIG. 3. This stitched line preferably is formed by stitching thematerials together and applying sealants preferably to an inside of thestitching sufficient to waterproof the seam and its stitching.

[0025] Each of the vamp 18 and heel counter 20 are preferably formedwith a sheet-like material forming their exterior surface, whichsheet-like material can permanently carry surface contours such asdeformations therein or ridges thereon which provide a pleasing,decorative appearance. In this regard, as best seen in FIG. 5, the vampis provided with a series of shallow grooves therein which provide apleasing appearance. In the particular embodiment shown in the groovesinclude a groove 58 which delineates an imitation toe counter portion60. Further, a plurality of decorative grooves 62 extend radiallyinwardly from the groove 58 to the upper edge 34 to provide a decorativeappearance.

[0026] In a somewhat similar manner, the exterior surface of the heelcounter 20 carries an oval depression 63 and raised lettering thereinrepresenting a trade mark of the boot manufacture provide the manner ofgrooves and/or a relief permanently formed in the exterior surface ofthe heel counter.

[0027] Each of the vamp 18 and heel counter 20 preferably have an outersheet which comprises a plastic material. The plastic material may beselected from vinyl, urethane, rubber and other plastic materials andcomposites and copolymers thereof. The plastic material preferably iswaterproof in the sense of preventing water and moisture to passtherethrough and not retaining water therein. Preferred of suchmaterials is vinyl. The surface of the outer sheet, preferably vinylmaterial, is preferably treated by being passed through a roller whichremoves a previously existing surface from the vinyl material so as toprovide an altered surface, preferably an embossed surface. The surfaceis preferably selected to have a surface similar to that of leather orsuede-like material with slight indentations and giving a slightlydistressed look similar to that of suede or leather. Preferably thesurface is not shiny. The outer sheet preferably must be selected suchthat after treating the surface, the material is waterproof.

[0028] Grooves 58 and 62 are preferably permanently imprinted using ahigh frequency welding technique under which high frequency sound wavesare directed into the vinyl at a time when the vinyl is being deformedby a printing plate or roller so as to permanently deform the outervinyl layer with the groove, surface detail etchings, patterns, relief,embroidering and the like. As well, decorative features such as falsestitching lines or joining seams may be formed. Other decorativefeatures can be provided such as raised areas and ribs and the like.

[0029] Each of the vamp 18 and heel counter 20 preferably comprise alaminate having a preferred outer layer of vinyl material. Preferably,inner layers of reinforcement and/or insulation materials may beprovided secured as an inner layer of the vamp and heel counter. FIG. 8shows an enlarged cross-section of the vamp showing an outer layer ofvinyl material 68 and an inner layer of backing material 70.

[0030] In accordance with the present invention, the vamp 18 and heelcounter 20 are formed to have preferred grooves and surface texture. Ina cement lasting process, the insole board 16 is placed on a last andthe vamp 18 and heel counter 20 are secured to the insole board 14 as byadhering the flanges 40 and 54 to the under surface 38 of the insoleboard 16. Subsequently, an assembly including the insole board 16, vamp18 and heel counter 20 are placed on the sole 12 sandwiching the filler14 therebetween.

[0031] The insole board 16 and filler 14 are preferably secured to thesole 12 by a double bonding process in which a layer of waterimpermeable sealing and/ or adhesive compound is provided as acontinuous layer schematically shown as 100 in FIG. 10 over the entirelower surface of the lasting allowance flanges 40 and 54 of the vamp andcounter and over the entirety of the lower surface 38 of the insoleboard 16 so as, for example, to provide a impermeable seal against waterpassing through the composite structure formed by the insole board 16,vamp 18 and heel counter 20. In addition, additional cementing isprovided as a continuous secondary seal area, bead or joint 102 aboutthe periphery of the sole 12 where an upper rim 104 of the sole 12merges with the vamp 18 and heel counter 20 circumferentially about thesole 12 as seen in FIG. 10.

[0032]FIG. 9 shows a resultant assembly comprising a boat-like shell 72which may be produced as a composite of the sole 12, filler 14, insoleboard 16, vamp 18 and heel counter 20. While the insole board 16, vamp18 and heel counter 20 are joined by a cement lasting process by the useof a water impermeable injected rubber sole 12, a water impermeablevinyl sheeting for each of the vamp 18 and heel counter 20 and withproviding for water impermeable joining of the vamp 18 to the heelcounter 20 and water impermeable joining of the vamp 18 and heel counter20 to the sole 12 as well as the preferred undercoating of the flangeportions of the vamp and heel counter and the under surfaces of theinsole board 16 with waterproof surface coating adhesives, the boat-likeshell comprises effectively a waterproof vessel made by the cementlasting process. This waterproof boat-like shell may preferably comprisea lower portion of a footwear which may adopt and have varying upperswhich may be laced or slide on or may be of varying heights. Theboat-like shell will be used with a shaft or collar which extendsupwardly as in a manner of the boot shown or may be very shallow as inthe manner of providing a slipper or the like.

[0033] The novel selection of the particular elements of construction,namely, the relatively lightweight injection-molded sole, the vinyl vampand vinyl heel counter carrying a decorative surface and decorativegrooves therein provide for a novel construction which is relativelyinexpensive to manufacture yet can be perfectly waterproof and has theappearance of the well known accepted one-piece boat-like shells.

[0034] While the vamp 18 is shown as one piece as is preferred to reduceseams which must be waterproofed, the vamp 18 may comprise a number ofpieces of sheet material as with a separate toe counter or piecesbetween.

[0035] Many modifications and variations of the invention will now occurto persons skilled in the art. For a definition of the invention,reference is made to the appended claims.

1. A boat-like shell for a footwear comprising a sole, a vamp, a heelcounter and an insole board, the sole comprising a water impermeableunitary member formed by injection molding, the vamp and heel countereach comprising a sheet of water impermeable plastic material, theinsole board having a lower surface and a perimeter thereabout, the vampand heel counter secured to the insole board to extend upwardly from theperimeter of the insole board and with flange portions of each of thevamp and heel counter folded to extend under the insole board and to besecured to the lower surface of the insole board, a layer of waterproofing adhesive applied over the flange portions of the vamp foldedunder the insole board and over the lower surface of the insole board toseal the lower surface of the insole board and junctures between theinsole board and the vamp and the heel counter against waterpenetration, the sole having a continuous upper rim in engagement withand encircling the vamp and counter, a continuous joint of waterimpermeable adhesive joining the upper rim of the sole to the vamp andheel counter continuously about the rim, the vamp having a toe portionextending over the toes and upper portion of the foot to enclose toesand an upper portion of a foot received in the footwear rearwardly fromthe toes at least rearward to above a ball of the foot.
 2. A boat-likeshell as claimed in claim 1 wherein the sheet of plastic material isvinyl and has an exterior surface comprising an exterior surface of thevamp, the exterior surface of the sheet of vinyl having surface contoursdefined therein.
 3. A boat-like shell as claimed in claim 2 wherein thesurface contours comprise a relief which provide an appearance of a toecounter formed on the vamp.
 4. A boat-like shell as claimed in claim 2wherein the surface contours comprise grooves which delineate a toeportion of the vamp about the toe from the remainder of the vamp andprovides he toe portion with an appearance of a toe counter formed onthe vamp.